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NASA NTRS2004

Evaluation of Double-Vacuum-Bag Process For Composite Fabrication

A non-autoclave vacuum bag process using atmospheric pressure alone that eliminates the need for external pressure normally supplied by an autoclave or a press is an attractive method for composite fabrication. This type of process does not require large capital expenditures for tooling and processing equipment. In the molding cycle (temperature/pressure profile) for a given composite system, the vacuum application point has to be carefully selected to achieve the final consolidated laminate net shape and resin content without excessive resin squeeze-out. The traditional single-vacuum- bag (SVB) process is best suited for molding epoxy matrix based composites because of their superior flow and the absence of reaction by-products or other volatiles. Other classes of materials, such as polyimides and phenolics, generate water during cure. In addition, these materials are commonly synthesized as oligomers using solvents to facilitate processability. Volatiles (solvents and reaction byproducts) management therefore becomes a critical issue. SVB molding, without additional pressure, normally fails to yield void-free quality composites for these classes of resin systems. A double-vacuum- bag (DVB) process for volatile management was envisioned, designed and built at the NASA Langley Research Center. This experimental DVB process affords superior volatiles management compared to the traditional SVB process. Void-free composites are consistently fabricated as measured by C-scan and optical photomicroscopy for high performance polyimide and phenolic resins.

Hou, T. H.↗
NASA NTRS2004

Fabrication of Microshutter Arrays for James Webb Space Telescope

Two-dimensional MEMS microshutter arrays are being developed at NASA Goddard Space Flight Center for use in the near-infrared region on the Next Generation Space Telescope (NGST). The microshutter arrays are designed for the selective transmission of light with high efficiency and high contrast. The NGST environment requires cryogenic operation at 45K. Microshutter arrays are fabricated out of silicon-oxide-insulated (SOI) silicon wafers. Arrays are close-packed silicon nitride membranes with a pixel size of 100x100 microns. Individual shutters are patterned with a torsion flexure permitting shutters to open 90 degrees with a minimized mechanical stress concentration. The mechanical shutter arrays are fabricated using MEMS technologies. The processing includes a multi-layer metal deposition and patterning of shutter electrodes and magnetic pads, reactive ion etching (RE) of the front side to form shutters out of the nitride membrane, an anisotropic back-etch for wafer thinning, followed by a deep RIE (DRIE) back-etch down to the nitride shutter membrane to form frames and relieve shutters from the silicon substrate. An additional metal deposition and patterning is used to form back electrodes. Shutters are actuated using a magnetic force and latched using an electrostatic force.

Li, Mary J.↗
NASA NTRS2004

Fabrication of MEMS-Based Microshutter Arrays for Optical Transmission Selection

A MEMS-based programmable aperture mask is under development at the NASA Goddard Space Flight Center. Termed the Microshutter (u-shutter) Array, the device will be used to control the transmission of light, with both high efficiency and contrast, to a multi-object spectrometer on the James Webb Space Telescope. Fabrication of the p-shutter array employs several novel designs and processing techniques. The current generation of micro-shutters consists of 128x64 pixel arrays with unit cell dimensions of 100x200 microns. Shutters are patterned in silicon nitride and sit on a 100 micron silicon frame that is DRIE etched below each shutter. The front and back sides of the device are shown. A magnetic cobalt-iron alloy patterned on top of the shutter allows it to be actuated 90 degrees out-of-plane, into the frame, by an external magnetic field. An electrode on the shutter and a vertical electrode on the sidewall of the frame, approximately 90pm deep, allow them to be electrostatically latched in their rotated position. The vertical electrode is deposited and patterned on the backside of the frame in a single step using a directionally controlled evaporation. Individual addressing of shutters for electrostatic latching is accomplished via a crosspoint addressing scheme, with no on-chip active components. A portion of an array with shutters in the open, latched, and closed positions is shown. Light loss at shutter edges is minimized by an overhanging aluminum light-shield that is anchored to the frame. A photoresist sacrificial layer is used to raise the light-shield up and over the 2 micron gap that surrounds each pixel. After completion, arrays are subjected to life cycle, environmental and optical testing. Fabricated devices have survived 10(exp 6) actuation cycles at both room and cryogenic temperatures and a 14g rms launch-simulation test. Optical testing has shown contrast measurements between open and closed shutters up to 10000:1.

Lynch, Bernard A.↗
NASA NTRS2004

Fabrication and Vibration Results of 30-cm Pyrolytic Graphite Ion Optics

Boeing Electron Dynamic Devices, Inc. is currently developing pyrolytic graphite (PG) grids designed to operate on 30-cm NSTAR-type thrusters for the Carbon Based Ion Optics (CBIO) program. The PG technology effort of the CBIO program aims to research PG as a flightworthy material for use in dished ion optics by designing, fabricating, and performance testing 30-cm PG grids. As such, PG grid fabrication results will be discussed as will PG design considerations and how they must differ from the NSTAR molybdenum grid design. Surface characteristics and surface processing of PG will be explored relative to effects on voltage breakdown. Part of the CBIO program objectives is to understand the erosion of PG due to Xenon ion bombardment. Discussion of PG and CC sputter yields will be presented relative to molybdenum. These sputter yields will be utilized in the life modeling of carbon-based grids. Finally, vibration results of 30-cm PG grids will be presented and compared to a first-order model generated at Boeing EDD. Performance testing results of the PG grids will not be discussed in this paper as it has yet to be completed.

DePano, Michael K.↗
NASA NTRS2004

Effect of Surface Treatments on Electron Beam Freeform Fabricated Aluminum Structures

Electron beam freeform fabrication (EBF3) parts exhibit a ridged surface finish typical of many layer-additive processes. This, post-processing is required to produce a net shape with a smooth surface finish. High speed milling wire electrical discharge machining (EDM), electron beam glazing, and glass bead blasting were performed on EBF3-build 2219 aluminum alloy parts to reduce or eliminate the ridged surface features. Surface roughness, surface residual stress state, and microstructural characteristics were examined for each of the different surface treatment to assess the quality and effect of the surface treatments on the underlying material. The analysis evaluated the effectivenes of the different surface finishing techniques for achieving a smooth surface finish on an electron beam freeform fabricated part.

Taminger, Karen M. B.↗
NASA NTRS2004

E-beam-Cure Fabrication of Polymer Fiber/Matrix Composites for Multifunctional Radiation Shielding

Aliphatic polymers were identified as optimum radiation polymeric shielding materials for building multifunctional structural elements. Conceptual damage-tolerant configurations of polyolefins have been proposed but many issues on the manufacture remain. In the present paper, we will investigate fabrication technologies with e-beam curing for inclusion of high-strength aliphatic polymer fibers into a highly cross-linked polyolefin matrix. A second stage of development is the fabrication methods for applying face sheets to aliphatic polymer closed-cell foams.

Wilson, John W.↗
NASA NTRS2004

Fabrication and Testing of Binary-Phase Fourier Gratings for Nonuniform Array Generation

This effort describes the fabrication and testing of binary-phase Fourier gratings designed to generate an incoherent array of output source points with nonuniform user-defined intensities, symmetric about the zeroth order. Like Dammann fanout gratings, these binary-phase Fourier gratings employ only two phase levels to generate a defined output array. Unlike Dammann fanout gratings, these gratings generate an array of nonuniform, user-defined intensities when projected into the far-field regime. The paper describes the process of design, fabrication, and testing for two different version of the binary-phase grating; one designed for a 12 micron wavelength, referred to as the Long-Wavelength Infrared (LWIR) grating, and one designed for a 5 micron wavelength, referred to as the Mid-Wavelength Infrared Grating (MWIR).

Keys, Andrew S.↗
NASA NTRS2005

Back to the Future: A Historical Perspective of Lunar and Martian In-situ Fabrication and Repair

Scientists, engineers, and the general public have always speculated and dreamed about living and working on other planets. The allure and challenges of this endeavor have generated innumerable Conferences, feasibility studies and six manned Moon landings. As NASA prepares to return to the Moon and eventually Mars, it is only natural to stand on the shoulders of those giants who have gone before us. This time, as we go to stay, the development of processes that maximize the use of in-situ resources will become even more important. On demand fabrication of piece-parts to reduce required spares, development of habitat structures, and the ability to make repairs will all benefit from the use of in-situ materials including raw regolith and metals and/or gases extracted from regolith or planetary atmospheres. To support these activities, there will also be a need for recycling as well as non-destructive evaluation technologies. This paper will present a historical overview of technology development associated with In-Situ Fabrication and Repair (ISFR) elements described above and discuss the ISFR program implemented at NASA/Marshall Space Flight Center.

Bassler, Julie A.↗
NASA NTRS2005

Fabrication end Deployment Testing of Meter Solar Sail Quadrants for a Scaleable Square Solar Sail Ground Test System

In order for solar sail propulsion technologies to be considered as a viable option for a wide range of near term practical missions a predictable, stable, reliable, manufactureable, scaleable, and cost effective system must be developed and tested first on earth and then on orbit. The design and development of a Scaleable Square Solar Sail System (S^4) is well underway a t AEC-Able Engineering Co. Inc., and the design and production of the Solar Sails for this system is being carried out by SRS Technologies. In April and May of 2004 a single quadrant 10-meter system was tested at NASA LARC's vacuum chamber and a four quadrant 20-meter system has been designed and built for deployment and testing in the Spring of 2005 at NASA/Glenn Research Center's Plumb Brook Facility. SRS has developed an effective and efficient design for triangular sail quadrants that are supported are three points and provide a flat reflective surface with a high fill factor. This sail design is robust enough for deployments in a one atmosphere, one gravity environment and incorporates several advanced features including adhesiveless seaming of membrane strips, compliant edge borders to allow for film membrane cord strain mismatch without causing wrinkling and low mass (3% of total sail mass) ripstop. This paper will outline the sail design and fabrication process, the lessons learned and the resulting mature production, packaging and deployment processes that have been developed. It will also highlight the scalability of the equipment and processes that were developed to fabricate and package the sails. Based on recent experience, SRS is confidant that flight worthy solar sails in the 40-120-meter size range with areal density in the 4-5g/sq m (sail minus structure) range can be produced with existing technology. Additional film production research will lead to further reductions in film thickness to less than 1 micron enabling production of sails with areal densities as low as 20 g/sq m using the current design resulting in a system areal density of as low as 5.3g/sq m. These areal densities are low enough to allow nearly all of the Solar Sail missions that have been proposed by the scientific community and the fundamental technology required to produce these sails has been demonstrated on the ground test sails that have recently been built. These demonstrations have shown that the technology is mature enough to build sails needed to support critical science missions. Solar Sails will be an enabling technology for NASA's Vision for Space Exploration by allowing communication satellite orbits that can maintain continuous communication with the polar regions of the Moon and Mars and to support solar weather monitoring to provide early warning of solar flares and storms that could threaten the safety of astronauts and other spacecraft.

Laue, Greg↗
NASA NTRS2005

In Situ Fabrication Technologies

A manufacturing system is described that is internal to controlled cabin environments which will produce functional parts to net shape with sufficient tolerance, strength and integrity to meet application specific needs such as CEV ECLS components, robotic arm or rover components, EVA suit items, unforeseen tools, conformal repair patches, and habitat fittings among others. Except for start-up and shut-down, fabrication will be automatic without crew intervention under nominal scenarios. Off-nominal scenarios may require crew and/or Earth control intervention. System will have the ability to fabricate using both provisioned feedstock materials and feedstock refined from in situ regolith.

Rolin, Terry D.↗
NASA NTRS2004

Processing Techniques Developed to Fabricate Lanthanum Titanate Piezoceramic Material for High-Temperature Smart Structures

Piezoelectric ceramic materials are potential candidates for use as actuators and sensors in intelligent gas turbine engines. For piezoceramics to be applied in gas turbine engines, they will have to be able to function in temperatures ranging from 1000 to 2500 F. However, the maximum use temperature for state-of-the-art piezoceramic materials is on the order of 300 to 400 F. Research activities have been initiated to develop high-temperature piezoceramic materials for gas turbine engine applications. Lanthanum titanate has been shown to have high-temperature piezoelectric properties with Curie temperatures of T(sub c) = 1500 C and use temperatures greater than 1000 C. However, the fabrication of lanthanum titanate poses serious challenges because of the very high sintering temperatures required for densification. Two different techniques have been developed at the NASA Glenn Research Center to fabricate dense lanthanum titanate piezoceramic material. In one approach, lower sintering temperatures were achieved by adding yttrium oxide to commercially available lanthanum titanate powder. Addition of only 0.1 mol% yttrium oxide lowered the sintering temperature by as much as 300 C, to just 1100 C, and dense lanthanum titanate was produced by pressure-assisted sintering. The second approach utilized the same commercially available powders but used an innovative sintering approach called differential sintering, which did not require any additive.

Goldsby, Jon C.↗
NASA NTRS2001

Biaxial Testing of High-Strength Fabric Improves Design of Inflatable Radar Domes

Large radar installations around the globe continuously watch the skies, unobtrusively providing security to the United States; these systems have been in active use for the past 50 years. Often situated in extreme environments, the radar dishes require shielding from the harsh elements. Air-inflated domes (over 100 ft in diameter) are one structure of choice for providing this essential protection. The radomes are constructed from highstrength fabric that is strong enough to withstand the inflation pressure, high winds, and other environmental loads, yet transparent to the microwave signal to allow precise radar mapping. This fabric is woven from glass fibers for high strength and embedded in a polytetrafluoroethylene resin matrix, akin to the nonstick coatings used on cookware.

Krause, David L.↗
NASA NTRS2003

Processing Methods Established To Fabricate Porous Oxide Ceramic Spheres for Thermal Barrier Coating Applications

As gas turbine technology advances, the demand for efficient engines and emission reduction requires a further increase in operating temperatures, but combustion temperatures are currently limited by the temperature capability of the engine components. The existing thermal barrier coating (TBC) technology does not provide sufficient thermal load reduction at a 3000 F (1649 C) operating condition. Advancement in thermal barrier coating technology is needed to meet this aggressive goal. One concept for improving thermal barrier coating effectiveness is to design coating systems that incorporate a layer that reflects or scatters photon radiation. This can be achieved by using porous structures. The refractive index mismatch between the solid and pore, the pore size, and the pore density can be engineered to efficiently scatter photon radiation. Under NASA s Ultra-Efficient Engine Technology (UEET) Program, processing methods to fabricate porous ceramic spheres suitable for scattering photon radiation at elevated temperatures have been established. A straightforward templating process was developed at the NASA Glenn Research Center that requires no special processing equipment. The template was used to define particle shape, particle size, and pore size. Spherical organic cation exchange resins were used as a structure-directing template. The cation exchange resins have dual template capabilities that can produce different pore architectures. This process can be used to fabricate both metal oxide and metal carbide spheres.

Dynys, Frederick W.↗
NASA NTRS2003

Novel Engineering and Fabrication Techniques Tested in Low-Noise- Research Fan Blades

A major source of fan noise in commercial turbofan engines is the interaction of the wake from the fan blades with the stationary vanes (stators) directly behind them. The Trailing Edge Blowing (TEB) project team at the NASA Glenn Research Center designed and fabricated new fan blades to study the effects of fan trailing edge blowing as a potential noise-reduction concept. The intent is to fill the rotor wake by supplying air to the rotor blade trailing edge at the proper conditions to minimize the wake deficit, and thus generate less noise. The TEB hardware is designed for the Active Noise Control Fan (ANCF) test rig in Glenn's Aeroacoustic Propulsion Laboratory. For this test, the air is fed from an external supply through the shaft of the rig. It is distributed to the base of each blade through an impeller, where it is forced into a plenum at the core of each blade. In actual engine configuration, air would most likely be bled from the compressor, but only at times when noise is an issue, such as takeoffs and landings. Glenn researchers designed and manufactured the blades in-house, using new techniques and concepts. The skins, which were designed for maximum strength in the directions of highest stress, were molded from multiple layers of carbon fiber. Considerable use was made of rapid prototyping techniques, such as laser sintering. The core was sintered from a lightweight polymer, and the retainer was CNC-machined (computer numerical control machined) from aluminum. All the components were joined with a cold-cure aerospace adhesive. These techniques and processes reduced the overall cost and allowed the new concept to be studied much sooner than would be possible using traditional fabrication methods. Since this test rig did not support the use of blade-monitoring techniques such as strain gauges, extensive bench testing was required to qualify the design. The blades were examined using a variety of methods including holography, pull tests (cyclic and failure), shake tests, rap tests, and nondestructive inspection. Acoustic testing of the ANCF fan using TEB has been ongoing since January of 2001. The fan has completed about 100 hr of testing with no structural, vibrational, or fatigue problems. Far-field acoustic measurements, in-duct mode measurements, precise hot wire surveys, and detailed performance measurements are providing data for evaluating the concept. The far-field noise data show that tone noise was reduced significantly with the initial ANCF TEB fan design. In addition, a significant reduction in unsteady stator loading has been measured, indicating the potential for stator broadband noise reduction. The acoustic benefits will be assessed and important design parameters identified to improve the ability to fully exploit any benefit provided by this technique. On the basis of the success of trailing edge blowing, Glenn plans to continue this research with a higher speed, higher pressure ratio fan operating in an acoustic wind tunnel to simulate flight conditions.

Cunningham, Cameron C.↗
NASA NTRS2003

Packaging Technology Designed, Fabricated, and Assembled for High-Temperature SiC Microsystems

A series of ceramic substrates and thick-film metalization-based prototype microsystem packages designed for silicon carbide (SiC) high-temperature microsystems have been developed for operation in 500 C harsh environments. These prototype packages were designed, fabricated, and assembled at the NASA Glenn Research Center. Both the electrical interconnection system and the die-attach scheme for this packaging system have been tested extensively at high temperatures. Printed circuit boards used to interconnect these chip-level packages and passive components also are being fabricated and tested. NASA space and aeronautical missions need harsh-environment, especially high-temperature, operable microsystems for probing the inner solar planets and for in situ monitoring and control of next-generation aeronautical engines. Various SiC high-temperature-operable microelectromechanical system (MEMS) sensors, actuators, and electronics have been demonstrated at temperatures as high as 600 C, but most of these devices were demonstrated only in the laboratory environment partially because systematic packaging technology for supporting these devices at temperatures of 500 C and beyond was not available. Thus, the development of a systematic high-temperature packaging technology is essential for both in situ testing and the commercialization of high-temperature SiC MEMS. Researchers at Glenn developed new prototype packages for high-temperature microsystems using ceramic substrates (aluminum nitride and 96- and 90-wt% aluminum oxides) and gold (Au) thick-film metalization. Packaging components, which include a thick-film metalization-based wirebond interconnection system and a low-electrical-resistance SiC die-attachment scheme, have been tested at temperatures up to 500 C. The interconnection system composed of Au thick-film printed wire and 1-mil Au wire bond was tested in 500 C oxidizing air with and without 50-mA direct current for over 5000 hr. The Au thick-film metalization-based wirebond electrical interconnection system was also tested in an extremely dynamic thermal environment to assess thermal reliability. The I-V curve1 of a SiC high-temperature diode was measured in oxidizing air at 500 C for 1000 hr to electrically test the Au thick-film material-based die-attach assembly.

Chen, Liang-Yu↗
NASA NTRS2003

Microsystems Fabrication Laboratory-New Class 100 Cleanroom Completed and Certified

A new Microsystems Fabrication Laboratory (MFL), a Class 100 cleanroom fabrication facility, was completed and certified in 2002 at the NASA Glenn Research Center. This facility, to be used by Glenn's Instrumentation and Controls Division, was designed and built as part of the NASA Construction of Facilities Program. The design, construction, and certification phases were managed by personnel from Glenn s Facilities and Test Engineering Division. Because of time constraints and the need for specialized cleanroom expertise, this 1000 ft2 laboratory was completed using a design-build procurement. Facility Planning & Resources (Pittsburgh, PA) was selected as the prime contractor and provided the architectural design and project management. A major subcontractor, AdvanceTEC, LLC (Richmond, VA), provided the mechanical and electrical design and performed the construction services. Throughout this fast-track project, Facilities and Test Engineering Division personnel provided overall project management and worked closely with the contractors to ensure that the customers needs were addressed and that the impact of the project implementation was minimized.

Borato, Frances M.↗
NASA NTRS2005

Fabrication and Characterization of High Temperature Resin/Carbon Nanofiber Composites

As part of ongoing efforts to develop multifunctional advanced composites, blends of PETI-330 and carbon nanofibers (CNF) were prepared and characterized. Dry mixing techniques were employed and the effect of CNF loading level on melt viscosity was determined. The resulting powders were characterized for degree of mixing, thermal and rheological properties. Based on the characterization results, samples containing 30 and 40 wt% CNF were scaled up to approx.300 g and used to fabricate moldings 10.2 cm x 15.2 cm x 0.32 cm thick. The moldings were fabricated by injecting the mixtures at 260-280 C into a stainless steel tool followed by curing for 1 h at 371 C. The tool was designed to impart high shear during the injection process in an attempt to achieve some alignment of CNFs in the flow direction. Moldings were obtained that were subsequently characterized for thermal, mechanical and electrical properties. The degree of dispersion and alignment of CNFs were investigated using high-resolution scanning electron microscopy. The preparation and preliminary characterization of PETI-330/CNF composites will be discussed.

Ghose, Sayata↗
NASA NTRS2006

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Taminger, Karen M.↗